SICK AOS502 STS Operating instructions

SUPPLEMENTARY OPERATING INSTRUCTIONS

AOS502 STS

Object Detection Systems

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Product described

Product name: AOS502 STS

Document identification

Title: AOS502 STS Supplementary Operating Instructions

Part number: 8017621/ZPQ5

Status: 2017-08-15

Manufacturer

SICK AG

Erwin-Sick-Str. 1 · 79183 Waldkirch · Germany

Trademarks

IBM is a trademark of the International Business Machine Corporation.

MS-DOS is a trademark of the Microsoft Corporation.

Windows is a trademark of the Microsoft Corporation.

Other product names in this document may also be trademarks and are

only used here for identification purposes.

Original documents

The German version 8017619/ZPQ5 of this document is an original SICK AG

document.

SICK AG does not assume liability for the correctness of a non-authorized

translation.

In case of doubt, contact SICK AG or your local agency.

Legal notes

Subject to change without notice

CONTENTS

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Contents

1 About these operating instructions ..............................................................................5

1.1 Purpose of this document .................................................................................... 5

1.2 Target group ......................................................................................................... 5

1.3 Information depth ................................................................................................ 6

1.4 Abbreviations used ............................................................................................... 6

1.5 Symbols used ....................................................................................................... 7

2 Safety ..............................................................................................................................8

2.1 Qualified personnel .............................................................................................. 8

2.2 Applications of the system ................................................................................... 8

2.3 Intended use ......................................................................................................... 9

2.4 General safety notes and protective measures ................................................. 9

3 Product description .................................................................................................... 10

3.1 Scope of delivery ............................................................................................... 10

3.2 System components ......................................................................................... 11

3.3 System functionality .......................................................................................... 12

4 Project planning .......................................................................................................... 14

4.1 Monitoring fields and evaluation cases ........................................................... 14

4.1.1 Prepared evaluation cases (EVCs) .................................................... 14

4.1.2 Input and output signals .................................................................... 15

4.2 Dimensioning the monitoring fields ................................................................. 16

4.2.1 Size and alignment of the fields for crane-to-ship collision

protection ........................................................................................... 16

4.2.2 Size and alignment of the fields for crane-to-crane collision

protection ........................................................................................... 17

4.2.3 Size and position of the test fields .................................................... 18

4.3 Scan plane ......................................................................................................... 20

4.3.1 Parallelism of the scan plane ............................................................ 20

4.3.2 Inclination angle of the scan plane ................................................... 21

5 Mounting ..................................................................................................................... 22

5.1 Mounting the laser scanners ............................................................................ 22

5.1.1 Position of the laser scanners ........................................................... 22

5.1.2 Inclination of the laser scanners ....................................................... 22

5.1.3 Mounting on booms with encompassing trolley ............................... 23

5.2 Position of the test target ................................................................................. 24

5.3 Mounting the Flexi Soft control ........................................................................ 24

6 Electrical installation ................................................................................................. 25

6.1 Electrical connection ......................................................................................... 25

6.1.1 Connection by means of individual installation cables .................... 25

6.1.2 Connection by means of distributor box ........................................... 27

6.1.3 General notes about the cables ........................................................ 29

6.2 Input and output signals of the AOS502 STS system ..................................... 30

7 Commissioning ............................................................................................................ 32

7.1 Configuration ..................................................................................................... 32

7.2 Checking the stopping and warning response of the system ......................... 32

CONTENTS

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8 Electrical wiring diagram ............................................................................................ 33

9 Appendix ....................................................................................................................... 37

9.1 List of tables .......................................................................................................37

9.2 List of figures ......................................................................................................38

ABOUT THESE OPERATING INSTRUCTIONS 1

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1 About these operating instructions

Please read this chapter carefully before you begin working with this documentation and

the AOS502 STS.

1.1 Purpose of this document

These supplementary operating instructions are intended to give technical personnel of

the machine manufacturer or operator instructions on the safe mounting, configuration,

electrical installation, commissioning, operation, and maintenance of the AOS502 STS

object detection system.

The supplementary operating instructions for the AOS502 STS object detection system

are only valid in conjunction with the underlying operating instructions for the AOS

Prime (8016731).

Unless otherwise specified in this document, the information in the underlying operating

instructions for the AOS Prime will apply.

1.2 Target group

These supplementary operating instructions are intended for persons who integrate the

AOS502 STS object detection system into a crane system, and initially commission and

operate it there. They are also intended for the planners, developers, and operators of

crane systems for the handling of goods and containers.

Note

1 ABOUT THESE OPERATING INSTRUCTIONS

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1.3 Information depth

These supplementary operating instructions contain information about the AOS502 STS

system on the following topics:

• Product description

• Project planning

• Mounting

• Electrical installation

• Commissioning

When planning and using the AOS502 STS system, technical skills are also required that

are not covered by this document.

The applicable official and legal regulations at the application site must always be

complied with when operating the system.

Further information about the device components used in the AOS502 STS can be found

in the accompanying operating instructions.

For carrying out the configuration and diagnostics of the AOS502 STS, you will need the

SOPAS SICK Engineering Tool (configuration software for the laser scanners), version

V 3.0 or higher, and the FSD Flexi Soft Designer (configuration and diagnostic software

for the control), version 1.7 or higher. Both of these tools are included in the scope of

delivery.

1.4 Abbreviations used

Advanced object detection system

Flexi Soft Designer = software for Flexi Soft control for configuration and diagnostics

Laser scanner from SICK AG

SICK Engineering Tool = software for laser scanner configuration and diagnostics

Programmable logic controller

Ship-to-shore

Note

AOS

FSD

LMS

SOPAS

PLC

STS

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1.5 Symbols used

Recommendations are designed to assist you in the decision-making process with respect

to the use of a certain function or technical measure.

Notes provide information about the features of a device, application tips, or other useful

information.

Instructions that must be carried out in the described order are referred to as step-by-step

instructions and are indicated by numbered lists. Carefully read and follow the

instructions for action.

Instructions for taking action are indicated by an arrow. Carefully read and follow the

instructions for action.

Recommendation

Note

1. / 2. ...

Step by step



Action

2 SAFETY

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2 Safety

This chapter concerns your own safety and the safety of the system operator.

▸

Please read through this chapter carefully before using the AOS502 STS or the crane

system monitored by the AOS502 STS.

Please also observe all safety notes contained in the operating instructions for the

components used.

2.1 Qualified personnel

The AOS502 STS must only be mounted, commissioned, and maintained by adequately

qualified personnel.

A qualified person

• has sufficient skills in the field of the respective equipment based on their technical

training and experience and

• has been instructed by the manufacturer in system operation and all applicable safety

guidelines and

• is familiar with all relevant country-specific occupational safety regulations, work safety

regulations, guidelines, and generally accepted technical rules and standards (e.g.,

DIN standards, VDE regulations, country-specific rules) to such an extent that he/she is

able to evaluate the safe condition of the power-driven machinery and he/she

• has access to and has read the operating instructions.

2.2 Applications of the system

The AOS502 STS object detection system is a collision protection system on ship-to-shore

crane systems or crane systems with a corresponding boom.

The system solution offers collision protection for the boom against ship constructions

with an upstream warning zone.

It offers additional collision protection with separate monitoring zones with respect to

neighboring cranes with lateral movements.

The ambient conditions typical in ports such as rain, snow, or fog, are mastered by the

AOS502 STS system.

Note

SAFETY 2

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2.3 Intended use

The AOS502 STS may only be used as described in section 2.2 Applications of the

system. The system may only be used by qualified personnel and only in industrial

environments in which it was installed and initially commissioned by qualified safety

personnel in accordance with these supplementary operating instructions.

The AOS502 STS object detection system is not a safety device for human protection

and it therefore does not comply with any safety standards. For safety applications,

please contact SICK AG.

2.4 General safety notes and protective measures

NOTE

These supplementary operating instructions must be made available to the operator of

the crane system on which the AOS502 STS system is used, along with the basic AOS

Prime underlying operating instructions.

The operator must be instructed by qualified safety personnel and read the operating

instructions.

Note

3 PRODUCT DESCRIPTION

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3 Product description

This chapter provides information on the special features of the AOS502 STS system.

It describes the construction and operating principle of the system, in particular the

interaction of the different components.

Always read this chapter before you mount, install, and commission the system.

3.1 Scope of delivery

The AOS502 STS consists of two pre-configured LMS511 laser scanners and the

Flexi Soft control, which comprises the main module and two I/O expansion modules.

The system is supplied with the required accessories.

Fig. 1: Main components of the AOS502 STS

Thorough check for completeness

▸

It is recommended that you carefully check for and report transport damage of any

kind as soon as possible after receiving the system.

▸

Also verify that the delivery includes all components listed on the delivery note.

Part No.

Quantity

Description

1064545

1

AOS502 STS

Consisting of:

Laser scanner

1057618

2

LMS511-10100S02 laser scanner

2063034

2

Connection box for power, I/O, and RS-232/RS-422 data

(not Ethernet), with three pre-wired M12 cables

2063050

2

Weather hood (180°), vertical mounting

2018303

2

Mounting kit for wall mounting (adjustment bracket)

2059271

2

Mounting bracket for mounting the laser scanner and

terminal box

6030928

2

Ethernet connection cable SSL-2J04-G10ME

Control

1043783

1

Flexi Soft main module FX3-CPU000000

1043700

1

Flexi Soft system plug FX3-MPL000001

1044125

2

Flexi Soft I/O module FX3-XTIO84002

6034574

1

Configuration cable DSL-8U04G02M025KM1 for connecting the

configuration connection of the Flexi Soft control to the USB

interface of the configuration PC

2073337

1

USB stick with configuration file (prepared configuration for control

and laser scanner) as well as device and system documentation

Tab. 1: Scope of delivery for the AOS502 STS

The “SOPAS” and Flexi Soft Designer configuration tools can be downloaded at

www.sick.com.

Note

Important note

Note

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3.2 System components

All components of the AOS502 STS system are prepared for their use on crane systems

for the handling of goods and containers.

LMS511 laser scanner with weather hood

The LMS511 laser scanners are designed for outdoor use in harsh ambient conditions

and are fitted with a weather protection hood. All input and output signals from the laser

scanners are directly connected to the central Flexi Soft control.

Fig. 2: LMS511 laser scanner with weather hood

The LMS511 laser scanners have a monitoring radius of 80 m / 38 m for black objects

with 10% remission and a scan angle of 190°.

They feature automatic contamination measuring for the front screen. The contamination

signals can be merged using the central Flexi Soft control and can be output via a shared

application diagnostic output.

The laser scanners are also equipped with an internal heater.

The Flexi Soft control

The Flexi Soft control for the AOS502 STS system consists of the CPU0 central main

module with a configuration memory and two XTIO I/O expansion modules.

The two I/O expansion modules provide the input and output signals from the AOS502

STS. The communication with the connected laser scanners and with the higher-level

crane control occurs via the switching signals.

The test target

The self-diagnosis of the object detection system occurs via the continuous detection of

an external test target. During this process, the corresponding scanner monitoring field is

infringed by the test target. Only by using external test targets can the full functional range

of the AOS502 STS system be ensured.

At least one test target is required to continue the self-diagnosis of the system. It is also

possible to use a common test target for several laser scanners.

In crane applications, such as ship-to-shore crane systems, a part of the crane body is

defined as the test target.

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Configuration

The configuration file contains all the functions required to evaluate the system based on

the scenarios at the industrial cranes and to cyclically test the laser scanners.

It is located on the USB stick supplied and is loaded onto the Flexi Soft control via file

download.

The size and geometry of the monitoring fields must be adapted to the existing conditions

on-site.

3.3 System functionality

The AOS502 STS is a self-testing object detection system whose functionality as a whole

is monitored by the Flexi Soft control. During later movement by a boom (gantry travel),

the system prevents collisions with exposed ship superstructures, such as the radar

system, and between neighboring cranes.

The AOS502 STS provides protection against collisions by means of two laser scanners,

which are positioned on the right and left sides of the boom. These generate a horizontal

monitored area along the boom, which covers its entire length.

In addition, depending on the mounting process, the system offers protection from

collisions with neighboring cranes during lateral movements through the monitored areas

oriented to the rear.

Fig. 3: Typical layout of the monitored areas

1

Crane-to-ship collision protection

2

Crane-to-crane collision protection

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If an object is detected in the monitored area, the system sends a slow-down signal

(warning signal) to the crane, followed by a stop signal, in case the crane is to continue

traveling.

For this purpose, the output signals of the laser scanners are evaluated and processed by

the Flexi Soft control.

As an option, relays can be controlled for the purposes of electrical isolation, e.g., the

SICK UE10-3OS safety relay.

Note

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4 Project planning

4.1 Monitoring fields and evaluation cases

The scanned area of the laser scanners is divided into different fields, known as

monitoring fields. The size and geometry of the monitoring fields can vary and must be

configured on-site depending on the installation position and the alignment of the laser

scanners.

The monitoring fields are adapted using the SOPAS configuration software supplied.

Each monitoring field is linked to an evaluation case (EVC). An evaluation case determines

the way the monitoring field is evaluated and which switching output is addressed.

Evaluation cases can be activated via input signals depending on the required scenarios.

Ten different evaluation cases can be configured and permanently saved in each laser

scanner. Depending on the input signals that are present for the evaluation case, the

laser scanner switches between the cases.

Fig. 4: Activating an evaluation case

4.1.1 Prepared evaluation cases (EVCs)

Every laser scanner is prepared with eight evaluation cases for use in the AOS502 STS.

Evaluation case

Field

LMS output

1

Boom stop

1

2

Test

2

3

Boom stop

2

4

Test

1

5

Boom warning

3

6

Crane-to-crane stop

4

7

Field 5*

5

8

Field 6*

5

9

Not used

10

Not used

Tab. 2: Pre-configured evaluation cases and switching signals

* Field 5 and field 6 are for additional demand. They can be used as desired, e.g. for a second

warning on the boom.

Monitoring fields

Evaluation cases

Legend

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4.1.2 Input and output signals

All input and output signals from the laser scanners are directly connected to the

Flexi Soft control.

The Out 1 to Out 5 LMS outputs signal the status of the assigned monitoring field to the

respective inputs of the Flexi Soft control.

The Flexi Soft control analyzes the status signals from the laser scanners based on the

stored monitoring scenarios and transmits corresponding stop and warning signals to

the higher-level crane control.

Fig. 5: Interaction between the input and output signals

LMS output Out 6 is used to signal the contamination of the laser scanner to the Flexi Soft

control. If contamination is low, a warning is displayed; if contamination is high, an error is

displayed.

Note

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4.2 Dimensioning the monitoring fields

With respect to their geometry, all monitoring fields must be adapted to the existing

conditions on-site.

The monitoring fields always start at the relevant laser scanner and span the stored

length and depth.

4.2.1 Size and alignment of the fields for crane-to-ship collision protection

The monitoring fields for the boom (crane-to-ship collision protection) are already pre-

defined as rectangles in the SOPAS configuration software. Typically, you will simply have

to adapt the specific dimensions.

The pre-assignment assumes that the laser scanner is positioned roughly in the center

of the monitored area.

Fig. 6: Size and alignment of the fields for crane-to-ship collision protection

By default, the monitoring fields for the booms are pre-defined with the following

dimensions:

Monitoring field

Depth

Width

Boom stop

3.5 m

50 m (± 25 m symmetrical with the center

of the LMS)

Warning/Speed reduction boom

7.5 m

50 m (± 25 m symmetrical with the center

of the LMS)

Tab. 3: Field sizes for crane-to-ship collision protection

The depth of the fields is generally based on the response time of the crane and its

stopping distance.

Fig. 7: Size of the warning field

▸

Increase or decrease the output field during the test drives systematically until the

slowing-down and stop procedures start to converge.

▸

Monitor the behavior of the crane during the test drives.

Warning field

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4.2.2 Size and alignment of the fields for crane-to-crane collision protection

The crane-to-crane collision protection can be used when the installation position and the

resulting inclination angle of the laser scanner allow this. Laser scanners with strong

inclination angles can only scan between the neighboring cranes to a certain degree. This

means a necessary stopping field cannot be completely covered.

A suitable layout for a stopping field can therefore not be determined. That is why the

evaluation cases and the stopping fields for the crane-to-crane collision protection are

predefined, but their geometries are not yet defined (empty).

The stopping fields should be wedge-shaped.

Due to the crane movements during operation, a suitable distance of the stopping field

to the crane body must be considered (distance d in the following figure). A minimum

distance of ≥ 0.5 m is recommended.

Fig. 8: Size and alignment of the fields for crane-to-crane collision protection

If the distance is too small, the monitoring field will impinge on the crane body and trigger

a stop erroneously.

Fig. 9: Distance between stopping field and crane body too low

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4.2.3 Size and position of the test fields

The system’s self-monitoring test fields are typically aligned with a suitable flat object

on the crane or directly with a flat area of the crane body. In the figure below, one of the

crane girders is used as the test target.

Fig. 10: Crane leg as test target

The test fields are pre-defined. They are formed as triangles and must be adapted to the

existing conditions on-site.

Fig. 11: Size and position of the test fields

By default, the test fields are pre-defined with the following dimensions in SOPAS:

Monitoring field

Length

Width at maximum length

Scan angle

Test field right/left

35 m

4 m

7° symmetrical

Tab. 4: Field sizes for the test fields

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The test fields on the right and left must clearly and reliably impinge on the crane girders.

Take into account tolerances resulting from mechanical movements.

In order to avoid reflections on the surface of the external test target, the area of the test

target must not be covered with a glossy coating.

Ideally, the test target should be outside the longest monitoring field (approx. 0.5 m from

the edge of the monitoring field). A standard value for the distance from the laser scanner

is > 0.5 m. The width of the test field on the test target must be at least 100 mm.

Fig. 12: Alignment of the test target on the crane body

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4.3 Scan plane

4.3.1 Parallelism of the scan plane

The scan plane of both laser scanners must be parallel to the boom (X = control

positions).

Fig. 13: Parallelism of the scan plane from the side

Larger deviations in terms of parallelism result in unintended shutdowns or detection

failures (X = control points).

Fig. 14: Incorrect scan plane from the side

Checking that the scan plane is correct

The scan plane can be correctly aligned using the scan finder, which you can order as

a SICK accessory.

Device

Accessories

Description

Part number

LS80b scan finder

Infrared receiver for locating the

laser beam

6020756

Alternatively, you can place suitable objects at two control points and check the scan

plane in the live monitor of the SOPAS configuration software.

Deviations can be corrected by swiveling the laser scanner.

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